Molded article laminated with fabric and method for reprocessing the same

ABSTRACT

The present invention relates to a molded article laminated with fabric wherein a thermoplastic resin (A) has a fabric, made up of fibers of a highly heat resisting thermoplastic resin (B), adhered to the surface thereof, wherein the thermoplastic resin (A) of the molding contains the highly heat resisting thermoplastic resin (B) constituting the fibers and wherein the highly heat resisting thermoplastic resin (B) is present as a microdispersion of melt-blended minute particles in the thermoplastic resin (A), and a method not only for reprocessing the mold flashes at the time of the preparation of molded articles laminated with fabric but also for reprocessing the defective molded articles laminated with fabric which come from the production line and are destined to be discarded.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part application related to U.S.Non-Provisional patent application Ser. No. 09/598,823, filed on Jun.21, 2000 now abandoned, which is a divisional application of then U.S.application Ser. No. 09/219,408, filed Dec. 23, 1998, now issued U.S.Pat. No. 6,451,417, and which claims priority from a Japanese patentapplication No. 9-369501 filed on Dec. 26, 1997. All applications areincorporated herein by reference for all purposes.

BACKGROUND OF THE INVENTION Technical Field of the Invention

The present invention relates to a molded article laminated with fabricwhich is prepared by adhering a fabric made up of highly heat resistingfibers to the surface of a molding produced from a thermoplastic resinand to a method for reprocessing the molded article laminated withfabric.

Plastic moldings, which are used in such applications as inner walls,partitions and doors of buildings, and head rests, arm rests and solidportions of console boxes of automobiles and which are molded articleslaminated with fabric, are described in Japanese patent applicationPublication (JP-B) No. 63-51,088.

In the case of the molded articles laminated with fabric described inJP-B No. 63-51,088, as will be seen in FIG. 1, a fiber sheet is presentin part of the mold flash when the molding is prepared. Generally, moldflashes which contain no fiber sheet are reprocessed without anytreatment. The mold flashes and defective moldings which contain a fibersheet are actually discarded without being reused. This is because theresidual fiber sheet brings about the problem that the difference inbulk density between fibrous portions and the resinous portions causesnonuniformity in the charging amount to an extruder thereby making theextruded amount unstable. In addition, the reuse of the mold flashescontaining a fiber sheet brings about the problem that fibrous lumpsremain on the surface of the moldings obtained thereby impairing theappearance and significantly reducing the physical strength of themoldings.

Accordingly, for the preparation of a mold article laminated withfabric, the mold structure needs to be designed so that the amount ofmold flashes is minimized. Despite such precaution in designing,however, fiber sheets needs to be carefully removed manually if the moldflashes containing the fiber sheets are reused.

In view of the actual situation where a large amount of molded articleslaminated with fabric are widely used in the field of automobileindustry, construction industry and the like, it is extremely difficultto manually remove the fiber sheets from the mold flashes in terms ofproductivity. Therefore, it is an inevitable consequence that the moldflashes are forced to be discarded in the face of the fact that therecycling of plastics is strongly encouraged.

SUMMARY OF THE INVENTION

Accordingly, an object of the present invention is to provide a methodnot only for reprocessing the mold flashes at the time of thepreparation of molded articles laminated with fabric but also forreprocessing the defective molded articles laminated with fabric whichcome from the production line and are destined to be discarded.

Another object of the present invention is to provide a method whichmakes it possible to prevent the impairment of the physical propertiesand appearance of the moldings prepared by reusing the resinous materialcontaining the fiber sheets and which enables accurate control of theparameters, such as wall thickness of the moldings, in the formingprocess.

The molded article laminated with fabric according to the presentinvention is a molding which is made from a thermoplastic resin (A) andhas a fabric, made up of fibers of a highly heat resisting thermoplasticresin (B), adhered to the surface thereof, wherein the thermoplasticresin (A) of the molding contains the highly heat resistingthermoplastic resin (B) constituting the fibers and wherein the highlyheat resisting thermoplastic resin (B) is present as minute particles inthe thermoplastic resin (A). The minute particles of the microdispersionare typically only a few microns in diameter, which is not performedwith existing processes. In a preferred embodiment the volume average ofthe minute particles is 10 microns or less. In the molded articlelaminated with fabric of the present invention, it is preferred that thecontent of the highly heat resisting thermoplastic resin (B) in thethermoplastic resin (A) does not exceed 20% by weight.

The method for reprocessing moldings according to the present inventionrelates to a method for reprocessing a molded article laminated withfabric which is made from a thermoplastic resin (A) and has a fabric,made up of fibers of a highly heat resisting thermoplastic resin (B),adhered to the surface thereof, wherein the method comprises charging anextruder with a crushed product obtained by finely crushing the moldedarticle laminated with fabric, melt-blending the crushed product at atemperature, which is within the range of from the melting point to atemperature 50° C. higher than the melting point of the highly heatresisting thermoplastic resin (B) constituting the fibers, to therebyproduce a blend resin, and extruding the blend resin from the extruderto thereby granulate the blend resin. The thermoplastic resin (B) in theform of large islands is converted into a microdispersion by blending inthe extruder and extruding the blend from the extruder. That is, themelt-blending by means of an extruder converts the resin present in theform of large islands into a microdispersion of minute particles.

The size of the minute particles is less than 20 microns, generally lessthan 10 microns, and is approximately 1 micron in a preferredembodiment. The term micordispersion referes to a mixture of at leasttwo compounds wherein one of the compounds is disposed as minuteparticles as explained herein. The micron sized particles of themicrodispersion distinguishes the present invention from the variousmacrodispersion processes of the state of the art. The large particlesused in existing processes and products are for structural purposes toreinforce the structure, whereas the present invention employs themicron particles for aesthetic purposes. Furthermore, state of the artprocesses teach away from using micron sized particles. Because of thismicrodispersion, even if the thermoplastic resin (A) is separated fromthe thermoplastic resin (B) at the interface thereof, the separation isvery minute and therefore the basic physical properties of thethermoplastic resin (A) are hardly influenced by the separation. As thepresent invention involves the combination of two compounds that wouldnot generally be combined, the manner in which the compounds arecombined is important as noted by the test results herein.

Conditions suited for the implementation of the method for reprocessinga molding according to the present invention are as follow. Themelt-blending temperature is within the range of from the melting pointto a temperature 30° C. higher than the melting point of the highly heatresisting resin constituting the fibers. The melt-blending time is 20 to600 seconds. The thermoplastic resin (A) is a polyolefinic resin, suchas high-density polyethylene or polypropylene, a polystyrene resin, anABS resin, a modified polyphenylene ether, or the like. Thethermoplastic resin (B) is nylon or polyester.

In the case of a crystalline thermoplastic resin, the melting point asreferred to in the present invention is a melting point measured bydifferential scanning calorimetry. In the case of a noncrystallinethermoplastic resin, the melting point is referred to in the presentinvention as a flow-starting temperature (a temperature at which a flowof 2 mm³/second is attained under a condition using a load of 100 Kg anda die having a diameter of 1 mm and a length of 10 mm) when measured bymeans of a flow tester in which the resin flows down.

Still other objects and advantages of the present invention will becomereadily apparent to those skilled in this art from the followingdetailed description, wherein only a preferred embodiment of theinvention is described, simply by way of illustration of the best modecontemplated for carrying out the invention. As will be realized, theinvention is capable of other and different embodiments, and its severaldetails are capable of modifications in various obvious respects, allwithout departing from the invention

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be readily understood by the followingdetailed description in conjunction with the accompanying drawings,wherein like reference numerals designate like structural elements, andin which:

FIG. 1 is an oblique view illustrating a molded article laminated withfabric.

FIG. 2 is a diagram illustrating a state where a parison and a fibersheet are disposed between mold halves.

FIG. 3 is a blow diagram flowchart illustrating the steps in the processfor forming the molded article laminated with fabric.

DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 illustrates a molded article laminated with fabric 1 that has ahollow double-wall structure in which the surface of the molding 2 has afabric 3 comprising a fiber sheet adhered thereto. The thermoplasticresin (A), which constitutes the molding 2, is a resin whose meltingpoint is lower than that of the thermoplastic resin (B) constituting thefibers. Examples of the thermoplastic resin (A) include high-densitypolyethylene, polypropylene, polystyrene resins, polyamide resins, softpolyvinyl chloride resins, hard polyvinyl chloride resins, ABS resins,AS resins, AES resins, and ASA resins as well as polyethyleneterephthalate resins, polybutylene terephthalate resins, modifiedpolyphenylene ethers, and elastomers, such as polyurethane elastomers,polystyrene elastomers, polyolefin elastomers, polyamide elastomers, andpolyester elastomers, each having a lower melting point in the range offrom 150 to 245° C.

Examples of the fiber sheet, which constitutes the fabric 3, include acloth, a knitting and a nonwoven fabric which are each obtained byprocessing synthetic fibers, such as polyamide, e.g., nylon 6 or nylon66, polyester, and the like, blends of these synthetic fibers, or blendfibers comprising such synthetic fibers and 20% or less of other fibers(e.g., natural fibers such as cotton, hemp, wool and silk, regeneratedfibers such as viscose rayon and cupro-ammonium rayon, semi-syntheticfibers such as acetate and triacetate, and synthetic fibers such asacrylic, vinylon, polypropylene and polyurethane).

One embodiment of the present invention is a molding 2 that is made froma thermoplastic resin (A) and has a fabric 3, made up of fibers of ahighly heat resisting thermoplastic resin (B), adhered to the surface.And, the thermoplastic resin (A) of the molding 2 contains a percentageof the highly heat resisting thermoplastic resin (B) constituting thefibers, wherein the highly heat resisting thermoplastic resin (B) arepresent as a microdispersion of melt-blended micron sized particles inthe thermoplastic resin (A). In one embodiment the volume average of theminute particles is 10 microns or less, and in a preferred embodimentthe minute particles are 1 micron or less. In the molded articlelaminated with fabric of the present invention, it is preferred that thecontent of the highly heat resisting thermoplastic resin (B) in thethermoplastic resin (A) does not exceed 20% by weight.

The molded article laminated with fabric 1, which is shown in FIG. 1, isobtained by a process comprising disposing a parison 6, which isextruded from an extrusion head 5, and a fabric 3 between mold halves 4and effecting blow-molding so that the fabric 3 adheres to the surfaceof the molding 2, as shown in FIG. 2. The parison is made from thethermoplastic resin (A) and contains a percentage of the highly heatresisting thermoplastic resin (B), wherein the highly heat resistingthermoplastic resin (B) is present as a microdispersion of melt-blendedmicron sized particles in the thermoplastic resin (A). In one embodimentthe volume average of the minute particles is 10 microns or less, and ina preferred embodiment the minute particles are 1 micron or less.

In the present state of the art, when a thermoplastic resin having afiber sheet adhered thereto is crushed in a crusher, the fiber sheet iscut into appropriate lengths thereby providing fibrous lumps having asize of several millimeters to tens of millimeters. Since the meltingtemperature of these fibrous lumps differs from that of thethermoplastic resin, which constitutes the molding to be prepared byblow-molding and which has a lower melting point, a molding producedfrom the blend of the fibrous lumps and the thermoplastic resin has apoor appearance because of the emergence of the fibers on the surface ofthe molding.

The industry teaches away from using small particles as it was believedthat the structural integrity could only be achieved with largerparticles. These prior process blends in the large sized fibers with thethermoplastic resin so that the fibers remain intact in the resultingproduct. This macrodispersion process employing millimeter sizedmacro-particles is intended to increase the strength of the end-product,but testing establishes that the desired strength is not obtainedbecause the fibers are basically infusible and remain in the form of thefibers themselves.

The present invention overcomes these problems, and provides a defectfree appearance with sufficient strength. A general explanation of theprocess is described herein, although other embodiments are within thescope of the invention. Referring to FIG. 3, in one embodiment, thethermoplastic resin (A) constituting the molding is polypropylene andthe highly heat resisting thermoplastic resin (B) constituting thefabric is a polyester resin (such as polyethylene terephthalate).According to the present invention, moldings or flashes having a fabricadhered thereto are crushed in a crusher 30. In this case, the polyesterresin constituting the fabric is in the form of aggregates of fibers cutinto a certain length and the aggregates are mixed with the crushedproduct of the polypropylene constituting the molding. The crushedproduct of polypropylene which constitutes the molding and the polyesterresin in the form of fibrous lumps are charged into an extruder 35 andkept at a temperature above the melting point of the polyester resin(thermoplastic resin (B)) for a certain period of time. This treatmentmelts the fibrous lumps of the polyester resin and converts them intoresinous lumps because the polyester resin is brought to a temperatureabove the melting temperature thereof.

As described herein, the size of the microdispersions is an importantelement of the present invention along with the melt-blending process,wherein the test results illustrate the ‘sweet spot’ achieved by thepresent invention. For example, suppose the lumps of the polyester andthe crushed polypropylene are not blended by means of a screw and arepresent as large particles. The lumps made up of molten polyester resinexist in the form of large islands in the polypropylene whichconstitutes the molding. Thus the polyester resin is present as largeislands in the polypropylene, providing something that resembles thefoam of sea after being melted and has generally poor aestheticqualities.

In addition, if the polypropylene and the polyester resin in the form offibrous lumps are kept at a temperature which is 50° C. higher than themelting point of the polyester resin, thermal degradation of theplastics takes place thereby exhibiting a remarkable impairment of thephysical properties.

Generally, a polyester resin is not compatible with a polypropyleneresin, and therefore these resins are not miscible with each other.Therefore, the state, where the polyester resin is present as largeislands in the polypropylene resulting in an appearance resembling the‘foam of sea’, results in a molding with a lessened mechanical strength.This is because even a very small external force easily separates thepolypropylene resin from the polyester resin at the interface thereof.

In order to overcome this problem, according to the present invention,the polyester resin in the form of large islands is converted into amicrodispersion by blending in an extruder and extruding the blend fromthe extruder. That is, the melt-blending of the crushed product 40 bymeans of an extruder converts the polyester resin present as the form oflarge islands or macro sized particles into a microdispersion of minuteparticles as the blended resin is extruded from the extruder 45. Thesize of the minute particles is 10 microns or less on average and lessthan 1 micron in a preferred embodiment. Thus, whereas the state of theart maintains the large particles in the product for perceivedstructural integrity, the present invention employs micron sizedparticles and a melt-blending so the micron sized particles ofthermoplastic resin B become integral with the thermoplastic resin A.

Because of this microdispersion, even if the polypropylene resin isseparated from the polyester resin at the interface thereof, theseparation is very minute and therefore the basic physical properties ofthe polypropylene are hardly influenced by the separation.Microdispersion is used herein to describe the dispersion of particleshaving a volume average diameter of 10 microns or less of a non-misciblematerial within a second material.

Accordingly, the present invention does not increase the rigidity byincreasing the compatibility between the two components. Since thepolyester resin is dispersed in the state of minute particles, thepresence of the polyester exerts almost no influence on the basicphysical properties of the polypropylene as a whole. Because of this, noadditive or filler is needed for the purpose of the compatibilization.Use of a conventional extruder brings about the desired result. Theextruder in the present invention may be a single-screw extruder or atwin-screw extruder. An extruder which exhibits an excellent blendingperformance is particularly preferred. Although a twin-screw extruder isknown to exhibit an excellent blending performance, a single-screwextruder provided with a high-performance blending section, such asMaddox screw with flutes, Dalmage screw, or double-flight screw, isknown. Another suitable single-screw extruder is, for example, atwo-stage extruder in which screws are exchanged midway.

The blend resin, which is obtained by the above-described method of thepresent invention, can be satisfactorily used again for molding, such asblow molding, injection molding, or the like, by a conventional moldingmachine. Naturally, however, the molding temperature is a temperaturesuited for the molding of polypropylene (generally in the range of from170 to 220° C.) in the case where polypropylene is used as describedabove, because at this temperature, the polyester does not melt.Therefore, when molded in this way, the polyester resin constituting thefabric is present in an unmelted state as in the case of a traditionalmolding operation. The resultant defect free article is derived from thepresent invention despite the fact that the polyester resin remainsunmelted as in the case of a traditional molding operation. This defectfree process is based on the phenomenon that the polyester resin ispresent in a state of microdispersion. If the polyester resin in thestate of fibrous lumps is melted and dispersed by means of an extruder,the fibrous lumps of the polyester resin is converted into particleswhich, even if unmelted, acts as a filler and contributes to theimprovement of the rigidity. It is known that if a certain amount of afiller, such as mica or talc, is incorporated into a thermoplasticresin, the physical properties such as rigidity of the molding made fromthe thermoplastic resin are improved. This type of filler is not in amolten state in the molten thermoplastic resin. The contribution to theimprovement of the physical properties, such as rigidity, of the moldingis due to the very microdispersion of the filler. The resin, whichconstitutes the fibers in the present invention and which is exemplifiedby the polyester resin, is not in a molten state in the moltenpolypropylene resin. The improvement of the rigidity is obtained becausethe polyester resin is present as minute particles and is dispersed inthe polypropylene resin.

Further, according to the present invention, the blend resin, afterbeing melted by dispersing the fibrous lumps by melt-blending, isextruded in the shape of strands which are then cut into pellets, orotherwise extruded in the shape of blocks which are then crushed bymeans of a crusher. In this way, the blend resin is granulated. Thegranules thus obtained are blended with a virgin resin or a regeneratedresin which is in a crushed state and does not contain fibrous lumps.The resulting blend is subjected to a molding operation, such as blowmolding, injection molding, extrusion molding, or the like, and thusrecycling is performed. In the present invention, since the blend resinis granulated, the granules can be charged into the molding machine in astable manner. Since the bulk density of the granules of the blend resinis similar to that of the virgin resin, these resins can be charged intothe molding machine uniformly.

As stated above, the method for reprocessing according to the presentinvention makes it possible to reuse the mold flashes of the moldedarticles laminated with fabric or the defective portions of the moldedarticles laminated with fabric which has been hitherto discarded.

Further, since the method for reprocessing according to the presentinvention makes it possible to process all of the fabric adhered to themoldings so that the fabric is mingled in new moldings, the method isuseful and advantageous to environments.

When the granules thus obtained are blended with a virgin resin, aregenerated resin, which is in a crushed state and does not containfibrous lumps, or a blend of these resins, so as to produce moldings,the moldings produced in this way are not limited to molded articleslaminated with fabric and naturally include moldings without the fabricadhered thereto.

EXAMPLES

The following examples are illustrative of the present invention and arenot limiting mechanisms of the scope of the present invention. Resinsused in a preferred embodiment include:

-   -   EC9 Polypropylene (hereinafter referred to as PP) manufactured        by Nippon Polychem Co., Ltd., with a melting point of 162° C.    -   B-871 Polyethylene (hereinafter referred to as PE) manufactured        by Asahi Chemical Industry Co., Ltd., with a melting point of        128° C.

The fiber sheets of the preferred embodiment are a needle punchedcarpet, which was made up of polyester fibers having a melting point of255° C. (hereinafter referred to a carpet A), and a tufted carpet, whichwas made up of cut pile of nylon 6 fibers having a melting point of 223°C. and a base fabric of polypropylene fibers having a melting point of162° C. (hereinafter referred to as carpet B), were used. In the carpetB, the weight ratio of the nylon fibers to the polypropylene fibers was3:1.

The extruder of the preferred embodiment, TEM75, was manufactured byToshiba Machine Co., Ltd. The screw diameter of this extruder was 75 mmand the motor had a power of 185 KW.

TABLE 1 Plastics Cloth Example 1 PP Carpet A Example 2 PP Carpet BExample 3 PE Carpet A Example 4 PE Carpet B Example 5 PP Carpet A

Example 1

The molded article laminated with fabric such as shown in FIG. 1 wasprepared by a blow-molding operation using PP as the thermoplastic resin(A) and the carpet A as the fabric. The machine used for the blowmolding operation was a molding machine which had a screw diameter of 90mm and an L/D ratio of screw of 24 and which was manufactured by NipponSteel Work Corp. The resin temperature of PP was about 200° C. and theblowing pressure was about 7 Kg/cm².

After blow molding, the peripheral flashes formed were separated intoportions having the fabric adhered thereto and portions having nofabric. Then, only the portions having the fabric adhered thereto werecrushed in a crusher so as to obtain crushed product consisting of cubeswhose sides were each about 7 mm long. The crushed product containedboth cloth and resin, wherein the weight ratio of the resin to the clothwas 90:10.

The crushed product was charged into the hopper of the TEM 75 extrudermanufactured by Toshiba Machine Co., Ltd., wherein the temperature ofthe extruder was set to the temperatures shown in Tables 2 and 3 and thecrushed product was kept in the extruder for retention times shown inTables 2 and 3. The crushed product was extruded from the head at thetip of the extruder so as to obtain strand-shaped resin having adiameter with cross-sectional area of about 3 mm. The strand was thencut into pellets, each having a length of 5 mm.

The pellets and virgin PP were blended so as to prepare a blendcomprising 80% of the virgin PP and 20% of the pellets. The blend wascharged into the single-screw extruder, wherein the resin temperaturewas set to 200° C. In this condition, a blow-molding operation wasperformed by using the mold, and thus a molded article laminated withfabric was obtained. In this case, the content of the fibrous resin was2%. For the purpose of the evaluation of the molding thus obtained, theappearance was visually inspected and reduction in strength was examinedby means of a tensile test (in accordance with JIS K 7113).

In the evaluation of the appearance the following symbols are used:

-   DF=a defect-free article;-   SD=a slightly defective article having, for example, localized    unmelted portions or excessively thin walls; and-   MD=an article having a molding defect.    In the test of strength, the following symbols are utilized:-   DF=the absence of reduction in tensile strength;-   SR=a slight reduction in tensile strength; and-   RR=a remarkable reduction in tensile strength.

TABLE 2 Recycled Temperture Time Pellet Virgin Pellet Evaluation Example(° C.) (sec) % % Appearance Strength Example 1-1 200 180 20 80 MD RRExample 1-2 230 180 20 80 MD RR Example 1-3 245 180 20 80 MD RR Example1-4 255 180 20 80 DF DF Example 1-5 265 180 20 80 DF DF Example 1-6 275180 20 80 DF DF Example 1-7 285 180 20 80 DF DF Example 1-8 300 180 2080 DF DF Example 1-9 315 180 20 80 DF RR Example 1-10 275 15 20 80 SD SRExample 1-11 275 20 20 80 DF DF Example 1-12 275 300 20 80 DF DF Example1-13 275 600 20 80 DF DF Example 1-14 275 700 20 80 DF RR

It can be seen that defect-free articles can be obtained if thetemperature for the formation of pellets is in the range of from 255 to300° C. (Example 1-4˜Example 1-8). If the retention time is 180 secondsfor the formation of pellets, the temperature is preferably is in therange of from 265 to 285° C. (Example 1-5˜Example 1-7).

If the temperature for the formation of pellets is 245° C. or below,defective appearance emerges (Example 1-1˜Example 1-3). If thetemperature for the formation of pellets is above 300° C., theproductivity in pellet production becomes worse and the physicalproperties of the moldings obtained become inferior.

It can be seen that proper time for melting for the formation of pelletsis in the range of from 20 to 600 seconds if the temperature is 275° C.If the time is 15 seconds, unmelted portions are present, whereaspelletization was impossible if the time was 700 seconds.

If the time was 700 seconds, the extrudate had a very low viscosity andwas in the state of syrup. Because of this low viscosity, the extrudatecould not be pulled to a pelletizer, and therefore the pelletization wasimpossible. The substance in the state of syrup was crushed and thecrushed product was subjected to the same blow-molding operation. Thestrength of the molding thus obtained was then subjected to a test oftensile strength, and it was found that the physical properties of thismolding were remarkably inferior.

Example 2

The procedure of Example 1 was repeated, except that the carpet A asused therein was replaced with the carpet B. The content of the fibrousresin was 2% by weight.

In the evaluation of the appearance the following symbols are used:

-   DF=a defect-free article;-   SD=a slightly defective article having, for example, localized    unmelted portions or excessively thin walls; and-   MD=an article having a molding defect.    In the test of strength, the following symbols are utilized:-   DF=the absence of reduction in tensile strength;-   SR=a slight reduction in tensile strength; and-   RR=a remarkable reduction in tensile strength.

TABLE 3 Recycled Temperature Time Pellet Virgin Pellet EvaluationExample (° C.) (sec) % % Appearance Strength Example 2-1 200 180 20 80MD RR Example 2-2 215 180 20 80 MD RR Example 2-3 225 180 20 80 SD DFExample 2-4 235 180 20 80 DF DF Example 2-5 245 180 20 80 DF DF Example2-6 255 180 20 80 DF DF Example 2-7 265 180 20 80 DF DF Example 2-8 275180 20 80 DF DF Example 2-9 285 180 20 80 DF DF Example 2-10 300 180 2080 DF DF Example 2-11 310 180 20 80 DF RR Example 2-12 255 15 20 80 SDSR Example 2-13 255 20 20 80 DF DF Example 2-14 255 300 20 80 DF DFExample 2-15 255 600 20 80 DF DF Example 2-16 255 700 20 80 DF RR

It can be seen that defect-free articles can be obtained if thetemperature for the formation of pellets is in the range of from 235 to300° C. (Example 2-4˜Example 2-10). If the retention time is 180 secondsfor the formation of pellets, the temperature is preferably in the rangeof from 235 to 265° C. (Example 2-4˜Example 2-7).

If the temperature for the formation of pellets is 225° C. or below,defective appearance emerges (Example 2-1˜Example 2-3). If thetemperature for the formation of pellets is above 300° C., pelletizationwas impossible.

If the temperature for the formation of pellets was above 300° C., theextrudate had a very low viscosity and was in the state of syrup.Because of this low viscosity, the extrudate could not be pulled to apelletizer, and therefore the pelletization was impossible. Thesubstance in the state of syrup was crushed and the crushed product wassubjected to the same blow-molding operation. The strength of themolding thus obtained was then subjected to a test of tensile strength,and it was found that the physical properties of this molding wereremarkably inferior.

It can be seen that proper time for melting for the formation of pelletsis in the range of from 20 to 600 seconds if the temperature is 255° C.If the time is 15 seconds, unmelted portions are present, whereas, ifthe time is 700 seconds or more, the time is too long and theproductivity in pellet production is poor. In addition, the physicalproperties of the moldings are inferior.

Example 3

The procedure of Example 1 was repeated, except that PP as used thereinwas replaced with PE. The content of the fibrous resin was 2% by weight.

In the evaluation of the appearance the following symbols are used:

-   DF=a defect-free article;-   SD=a slightly defective article having, for example, localized    unmelted portions or excessively thin walls; and-   MD=an article having a molding defect.    In the test of strength, the following symbols are utilized:-   DF=the absence of reduction in tensile strength;-   SR=a slight reduction in tensile strength; and-   RR=a remarkable reduction in tensile strength.

TABLE 4 Recycled Temperature Time Pellet Virgin Pellet EvaluationExample (° C.) (sec) % % Appearance Strength Example 3-1 200 180 20 80MD RR Example 3-2 230 180 20 80 MD RR Example 3-3 245 180 20 80 MD RRExample 3-4 255 180 20 80 DF DF Example 3-5 265 180 20 80 DF DF Example3-6 275 180 20 80 DF DF Example 3-7 285 180 20 80 DF DF Example 3-8 300180 20 80 DF DF Example 3-9 315 180 20 80 DF RR Example 3-10 275 15 2080 SD SR Example 3-11 275 20 20 80 DF DF Example 3-12 275 270 20 80 DFDF Example 3-13 275 600 20 80 DF DF Example 3-14 275 700 20 80 DF RR

It can be seen that defect-free articles can be obtained if thetemperature for the formation of pellets is in the range of from 255 to300° C. (Example 3-4˜Example 3-8). If the retention time is 180 secondsfor the formation of pellets, the temperature is preferably is in therange of from 265 to 285° C. (Example 3-5˜Example 3-7). If thetemperature for the formation of pellets is 245° C. or below, defectiveappearance emerges (Example 3-1˜Example 3-3).

It can be seen that proper time for melting for the formation of pelletsis in the range of from 20 to 600 seconds if the temperature is 275° C.If the time is 15 seconds, unmelted portions are present, whereas, ifthe time is 700 seconds or more, the time is too long and theproductivity in pellet production is poor. In addition, the physicalproperties of the moldings thus obtained are inferior.

Example 4

The procedure of Example 2 was repeated, except that PP as used thereinwas replaced with PE. The content of the fibrous resin was 2% by weight.

In the evaluation of the appearance the following symbols are used:

-   DF=a defect-free article;-   SD=a slightly defective article having, for example, localized    unmelted portions or excessively thin walls; and-   MD=an article having a molding defect.    In the test of strength, the following symbols are utilized:-   DF=the absence of reduction in tensile strength;-   SR=a slight reduction in tensile strength; and-   RR=a remarkable reduction in tensile strength.

TABLE 5 Recycled Temperature Time Pellet Virgin Pellet EvaluationExample (° C.) (sec) % % Appearance Strength Example 4-1 200 180 20 80MD RR Example 4-2 215 180 20 80 MD RR Example 4-3 225 180 20 80 SD DFExample 4-4 235 180 20 80 DF DF Example 4-5 265 180 20 80 DF DF Example4-6 285 180 20 80 DF DF Example 4-7 300 180 20 80 DF DF Example 4-8 310180 20 80 DF RR Example 4-9 325 180 20 80 DF RR Example 4-10 285 15 2080 SD SR Example 4-11 285 20 20 80 DF DF Example 4-12 285 300 20 80 DFDF Example 4-13 285 600 20 80 DF DF Example 4-14 285 700 20 80 DF RR

It can be seen that defect-free articles can be obtained if thetemperature for the formation of pellets is in the range of from 235 to300° C. (Example 4-4˜Example 4-7). If the retention time is 180 secondsfor the formation of pellets, the temperature is preferably in the rangeof from 235 to 265° C. (Example 4-4˜Example 4-5). If the temperature forthe formation of pellets is 225° C. or below, defective appearanceemerges (Example 4-1˜Example 4-3).

It can be seen that proper time for melting for the formation of pelletsis in the range of from 20 to 600 seconds if the temperature is 285° C.If the time is 15 seconds, unmelted portions are present, whereas, ifthe time is 700 seconds or more, the time is too long and theproductivity in pellet production is poor. In addition, the physicalproperties of the moldings thus obtained are inferior.

Example 5

The procedure of Example 1 was repeated, except that the weight of thefabric for the preparation of molded article laminated with fabric byblow molding was increased so that the ratio of the resin to the fabricin the crushed product was 70:30. The pellets obtained were each blendedwith a virgin material at the following ratios and respectiveblow-molded articles were obtained. The blending ratios for the recycledpellets were 40% by weight, 50% by weight, 60% by weight, 70% by weight,80% by weight, 90% by weight and 100% by weight; and wherein thecontents of the fibrous resin were 12% by weight, 15% by weight, 18% byweight, 21% by weight, 24% by weight, 27% by weight and 30% by weight,respectively.

In the evaluation of the appearance the following symbols are used:

-   DF=a defect-free article;-   SD=a slightly defective article having, for example, localized    unmelted portions or excessively thin walls; and-   MD=an article having a molding defect.    In the test of strength, the following symbols are utilized:-   DF=the absence of reduction in tensile strength;-   SR=a slight reduction in tensile strength; and-   RR=a remarkable reduction in tensile strength.

TABLE 6 Recycled Temperature Time Pellet Virgin Pellet Fibrous ResinEvaluation Example (° C.) (sec) % % % Appearance Strength Example 5-1275 180 40 60 12 DF DF Example 5-2 275 180 50 50 15 DF DF Example 5-3275 180 60 40 18 DF DF Example 5-4 275 180 70 30 21 SD DF Example 5-5275 180 80 20 24 MD SR Example 5-6 275 180 90 10 27 MD SR Example 5-7275 180 100 0 30 MD SR

It can be seen that defect-free articles can be obtained if the contentsof the fibrous resin in the molding are up to 20% by weight (Example5-1˜Example 5-3).

The objects and advantages of the present invention may be furtherrealized and attained by instrumentalities and combinations particularlypointed out in the appended claims. Accordingly, the drawing anddescription are to be regarded as illustrative in nature, and not asrestrictive.

1. A method for reprocessing a molded article laminated with fabric which is made from a first thermoplastic resin and has a fabric, made up of fibers of a second thermoplastic resin adhered to the surface thereof said second thermoplastic resin having a melting temperature higher than a melting point of said first thermoplastic resin, wherein the method comprises the steps: charging an extruder with a crushed product obtained by finely crushing the molded article laminated with fabric wherein said crushed product comprises less than 20% said second thermoplastic resin by weight; melt-blending the crushed product at a temperature, which is greater than said melting point of said second thermoplastic resin and not more than 50° C. above said melting point of said second thermoplastic resin, to thereby produce a blend resin having a microdispersion of said second thermoplastic resin within said first thermoplastic resin, wherein a particle size of said second thermoplastic resin has a volume average diameter of about 10 microns or less; and extruding the blend resin from the extruder to thereby granulate the blend resin.
 2. The method for reprocessing a molded article laminated with fabric according to claim 1, wherein the melt-blending temperature is within the range of from the melting point to a temperature 30° C. higher than the melting point of said second thermoplastic resin.
 3. The method for reprocessing a molded article laminated with fabric according to claim 1, wherein the melt-blending time is between 20 to 600 seconds.
 4. The method for reprocessing a molded article laminated with fabric according to claim 1, wherein said first thermoplastic resin is selected from the group consisting of a polyolefinic resin, high-density polyethylene, polypropylene, polystyrene resin, ABS resin, and modified polyphenylene ether.
 5. The method for reprocessing a molded article laminated with fabric according to claim 1, wherein said second thermoplastic resin is selected from the group consisting of nylon and polyester.
 6. The method for reprocessing a molded article laminated with fabric according to claim 1, wherein the granulated blend resin is blended with a virgin resin of said first thermoplastic resin, a regenerated resin thereof, or a mixture thereof and the resulting blend is subjected to blow molding.
 7. The method for reprocessing a molded article laminated with fabric according to claim 1, wherein the granulated blend resin is blended with a virgin resin of said first thermoplastic resin, a regenerated resin thereof, or a mixture thereof and the resulting blend is subjected to injection molding.
 8. The method for reprocessing a molded article laminated with fabric according to claim 1, wherein the granulated blend resin is blended with a virgin resin of said first thermoplastic resin, a regenerated resin thereof, or a mixture thereof and the resulting blend is subjected to extrusion molding.
 9. The method for reprocessing a molded article laminated with fabric according to claim 1, wherein the granulated blend resin is blended with a virgin resin of said first thermoplastic resin, a regenerated resin thereof, or a mixture thereof and the resulting blend is subjected to press forming.
 10. The method for reprocessing a molded article laminated with fabric according to claim 1, wherein the granulated blend resin is blended with a virgin resin of said first thermoplastic resin, a regenerated resin thereof, or a mixture thereof and the resulting blend is subjected to vacuum molding, compressed air molding, or vacuum/compressed air molding.
 11. The method for reprocessing a molded article laminated with fabric according to claim 1, wherein the granulated blend resin is blended with a virgin resin of said first thermoplastic resin, a regenerated resin thereof, or a mixture thereof in such a manner that the content of said second thermoplastic resin does not exceed 20% by weight of the total amount of the resulting blend.
 12. The method for reprocessing a molded article laminated with fabric according to claim 1, wherein a particle size of said second thermoplastic resin has a volume average diameter of about 1 micron or less. 